Note: Descriptions are shown in the official language in which they were submitted.
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FAN STATOR ASSEMBLY FOR HEAT EXCHANGER
; Background of the Invention
The present invention relates to air-moving fans, and is
more particularly directed to a heat exchanger assembly in which
a fan draws or forces air through a heat exchanger coil. The
invention specifically concerns the employment of a stator row
with a propeller fan which moves air through a heat exchanger
coil.
In a specific embodiment described hereafter, a stator
' row is applied beneficially to a packaged terminal air
conditioner (PTAC), and would also be appropriate for room air
conditioners or other similar devices.
A packaged terminal air conditioner is a unit having an
interior or indoor side connected to an exterior or outdoor side
through a penetration in a wall of a building. These units are
generally used both in summer as an air conditioner for cooling
and in winter as a heat pump for heating. The PTAC generally
uses the same motor and drive shaft to power a centrifugal fan on
the interior side and a propeller fan on the exterior side.
It has long been a goal in the industry to increase the
~ air moving efficiency of the fans. This yields a dual benefit of
requiring less electrical power and also reducing the noise level
due to the fans.
Although stators in general are well known, e.g., in
various compressors, they have not been used widely in the
heating, ventilation, and air conditioning tHVAC) field, and have
never been applied in PTAC units.
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One combination of propeller fan with a stator assembly
has been previously described in Gray, U.S. Pat. No. 4,548,548
for use in an automotive environment. In that patent, the fan is
intended to blow air through a heat exchanger, and a circular
S stator placed immediately after the fan to direct the exhaust
axially. The intention there is to remove rotational components,
and provide smoother air flow through the heat exchanger. The
stator assembly of the Gray patent forms part of the spider or
frame that suspends the fan and motor in front of the heat
~ exchanger. The stator there was also specifically intended for
~ use with a so-called banded fan where the fan blade tips are
! connected by a circumferential skirt. In the Gray patent, the
1 stator is circular in cross-section because it is integral to the
; fan-motor system and because it is designed to accommodate the
flow field dominated by the fan. This is good practice when
either the effective face area of the fan is approximately equal
to the face area of the coil, or the axis of the fan coincides
with the geometric center of the coil face.
However, when the face area of the coil is significantly
larger than the face area of the fan, and/or the axis of the fan
is offset from the geometric center of the coil, the stator
placement and geometry must account for diffusion in order to
achieve maximum benefit. This is critical because it is quite
difficult to diffuse or expand the airstream from the circular
geometry and discharge area of the fan to the larger and/or
offset rectangular geometry of the coil. Maximum diffusion is
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necessary to minimize the natural tendency towards non-uniform
air flow across the face of the coil with the concomitant
increase (relative to uniform flow) in air-side coil pressure
loss and under~utilization of heat transfer surface.
To maximize diffusion in order to achieve favorable
control of the above-mentioned effects, it is beneficial to place
the stator against the coil and to configure its overall geometry
to match the coil face area. This allows the centrifugal force
due to swirl to facilitate the outward diffusion process and,-
consequently, maximize uniform flow across the face of the coil.
If the stator were placed generally at the fan discharge (Gray
patent), the swirl velocity component would be removed prior to
the diffusion process and, hence, would be unavailable to achieve
the requisite diffusion.
Objects and Summary of the Invention
It is an object of this invention to recover a
significant part of the rotational energy from the discharge of a
propeller fan and convert it to useful form, such as increased
pressure, while maximizing uniform air flow across the coil face
and minimizing the angle between the coil fin pack and the
incident air velocity.
It is a related object of this invention to reduce fan
noise and fan shaft power requirements for a propeller fan that
is used with a heat exchanger coil.
In accordance with an aspect of this invention, a finned
condenser coil, or other heat exchanger coil, is combined with an
axial-flow propeller fan, a shroud, and a stator row disposed
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,_
substantially against the fan side of the coil. The heat
exchanger coil has a flat face and a plurality of fins that
define air passages between which air passes through the heat
exchanger. These passages thus are generally perpendicular to
this flat face. The axial flow propeller fan is positioned to
face the heat exchanger flat face with its axis passing through
the heat exchanger. However, in most cases, the fan axis is
displaced to one side or the other from the center of the heat
exchanger. The fan has a hub and a plurality of blades that .
radiate out from the hub, and is driven rotationally by an
electric motor or the like. The blades have a pitch that is
selected to impart a generally axially flow to the air when the
fan rotates. However, the flow also has a swirl component, i.e.,
a component in the tangential or circumferential direction. A
shroud is disposed over the fan and heat exchanger for guiding
the air into the fan. The shroud also ensures that the air is
forced through the heat exchanger and does not simply recirculate
to the intake side of the fan. The stator row is mounted on the
flat face of the heat exchanger and is substantially coextensive
with it. The stator row has an outer frame that substantially
matches the perimeter of the flat face, and a ring that is
substantial coaxial with the fan. A plurality of radial stator
vanes or blades extend from the ring to the frame and these vanes
have their pitch complementary to that of the fan blades. The
stator vanes turn the airstream until the air velocity is
generally axial. This transforms the swirl kinetic energy into a
more useful form of energy, by raising static pressure. This
also minimizes the angle between the coil fins and the incident
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airstream, hence reducing coil airside pressure loss.
Positioning the stator against the coil, rather than
placing it in the immediate vicinity of the fan discharge, takes
advantage of swirl in aiding diffusion prior to transforming
swirl into static pressure. Swirl centrifugates the airstream
; which promotes uniform flow over the face of the coil. Only
after this diffusion is maximized is the stator introduced to
eliminate swirl and transform it into static pressure. Since
maximum diffusion occurs, the flow field is dominated by the
presence and characteristic dimensions of the coil. Hence, the
optimal stator is configured to assume the generally rectangular
shape of the coil.
It should be understood-that a propeller fan in the air
flow circuit increases the fluid static pressure and kinetic
energy. The air flow leaving the fan blades has a velocity
vector V having both an axial component and a tangential
AF
component V . If nothing is done to recover the energy in the
., ~0
tangential component, this energy is eventually dissipated as
heat. That is, the swirl or tangential component represents work
done on the fluid and then lost. If the tangential component
; V can be recovered efficiently, then the loss attributable to
ao
; it is minimized. The change in this component V is recovered
; as an increase in static pressure. A stator row, which is a flat
arrangement of stationary stator blades or vanes, effectively
reduces this component V . That is, the air flow into the
stator row has the flow velocity V , while the air flow leaving
the stator row has a velocity V , which includes a significantly
smaller tangential component V . The difference between these
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components V90 and V6 , less some losses due to the presence of
the stator vanes, represents a conversion to static pressure at
the face of the heat exchanger. ~his conversion, in turn,
represents an increase in static pressure. Since the stator row
is now recovering what would otherwise be lost by converting
kinetic energy into static pressure, less fluid work is required
to generate the same static pressure as previously. Aiding this
process is a reduction in the static pressure requirements of the
system. This reduction results from a coil loss reduction as a
consequence of the reduced angle between the fin channel and the
incident airstream, and of the more uniform air flow across the
coil. Consequently, for the same system, a lower static-
pressure-rise fan, in conjunction with the stator row, can be
utilized in place of a high-pressure-rise fan without a stator.
This result~ in a much quieter operation and with significantly
less power required to deliver a given air flow rate.
In tests conducted in connection with the embodiment
described below, a 40~ reduction in shaft power and a 3.6 dBA
noise reduction have been realized owing to the stator row down
stream of the propeller fan on the outdoor or condenser side of a
PTAC. This was achieved without reduction in actual air flow
rate.
The above and many other objects, features and advantages
of this invention will be more fully appreciated from the ensuing
description of a preferred embodiment of the invention, which is
to be read in connection with the accompanying drawing.
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Brief Description of the Drawing
Fig. 1 is a schematic sectional plan view of a packaged
terminal air conditioner unit (PTAC) which incorporates the heat
exchanger, fan, and stator assembly according to one embodiment
of this invention.
Fig. lA is a supplemental view of a por~ion of the unit
of Fig. 1, for explaining the effect of the incidence angle of
air flow onto fins of the heat exchanger.
Fig. 2 is an exploded perspective view of the outdoor.or
condenser portion of the PTAC.
Fig. 3 is a front elevational view of a stator assembly
according to this embodiment of the invention.
Fig. 4 shows a typical stator vane or blade of the stator
assembly of Fig. 3.
Fig. 5 is a cross section of the stator vane of Fig. 4,
taken at lines 5-5 thereof.
Fig. 6 is a chart relating the ideal gas pressure rise
from a frictionless fan attributable to swirl velocity component
in a discharge air stream.
Fig. 7 is a schematic view taken in the radial direction
of the fan and stator assembly, showing the effect of the stator
assembly on the incidence of air onto the fins of the heat
exchanger.
Fig. 8 is a chart which compares the ideal gas pressure
rise of a frictionless propeller fan and a propeller fan with
stator assembly.
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Figs. 9 and 10 illustrate stator and fan arrangements for
full recovery and partial recovery of the swirl component,
respectively.
Detailed Description of the Preferred Embodiment
With reference to the Drawing, and initially to Fig. 1
thereof, a packaged terminal air conditioner (PTAC) unit 10 has
an indoor portion 12 which includes an evaporator coil 14 and a
centrifugal fan 16 mounted on a drive shaft 18. An outdoor
portion 20 includes a condenser coil 22 and a propeller fan 2.4
driven by the shaft 18. The fan 24 has a hub 26 mounted on the
shaft 18 and a number of blades 28 which radiate from the hub 26.
A shroud 30 extends over the coil 22 from a circular
opening 32 at the tips of the fan blades 28. The shroud 30
guides the air into the fan 24 and thence through the heat
exchanger coil 22. The shroud also serves to prevent
recirculation or looping of air through the fan.
As shown in Fig. lA, the air flow from the fan 24 is not
axial, but has its velocity vector 36 angled so as to strike fins
34 of the heat exchanger at a significant incidence angle.
Consequently, at the surface of the heat exchanger, the air flow
must bend to the axial direction to pass through the passages
between the fins 34. This large turn increases the pressure
losses through the heat exchanger.
In order to correct for swirl, a stator row 40 is
situated against the condenser coil 22 on the fan side thereof,
as illustrated, e.g., in Fig. 2. As further shown in Fig. 3, the
stator row 40 is oblong and rectangular, with a frame 42 that
substantially matches the periphery of the fan-facing side of the
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condenser coil 22. As the fan axis is eccentric with respect to
the coil 22, so the fan 24 has a forward projected area which is
much smaller than the area of the condenser coil 22. Also,
because of this geometry, a vane supporting ring 44 is situated
to one side of the center of the frame 42, to be coaxial with the
propeller fan 24. ~ suitable number of stator vanes 46 radiate
outward from the ring 44 to the peripheral frame 42. A typical
one of these vanes 46 is shown in Fig. 4. The vanes 46 are,
preferably, but not necessarily, substantially uniform in width
and shape from one end to the other, and are somewhat bowed or
arcuate in cross section, as shown in Fig. 5. At the ring 44,
the vanes 46 are spaced as close together, but not necessarily,
as possible. The frame 42, ring 44, and vanes 46 are preferably
molded unitarily from a plastic synthetic resin. An open area 48
lS within the ring 44 permits air to flow through it.
The operation and effectiveness of this assembly can be
understood from the following discussion, which concerns Figs. 6-
13.
For a frictionless or ideal fan with a blade stagger
of 150 degrees, the relative amount of pressure rise attributable
to the swirl velocity component in the discharge air stream is as
generally illustrated in Fig. 6. If the swirl velocity component
can be avoided or corrected, an amount up to the percentage shown
on the ordinate can be recovered, e.g., in the form of a higher
static pressure.
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The corrective effect of the stator row 40 can be
understood from Fig. 7. Here, for simplicity, a frictionless
ideal fan and an ideal stator are assumed. The fan blade 28, as
viewed in the fan's radial direction, is moving to the left of
S the page, and has a fan blade tip velocity vector UF as
illustrated. The forced air discharge velocity vector VRF,
i.e., the vector with respect to the fan blade, lies along the
direction of the trailing edge of the fan blade, as shown, while
the absolute fan discharge velocity vector VAF, i.e., the vector
with respect to the stator row 46, results from algebraically
combining the vectors VRF and UF . This velocity vector VAF has
a significant tangential component of discharge velocity V~0. If
uncorrected, as illustrated on the right hand side of Fig. 7, the
flow velocity vector 36 strikes the condenser coil fins 34 at a
large angle, and this results in significant pressure loss.
Moceover, V~0 represents kinetic energy added to the air stream
which is ultimately dissipated as heat. Hence, it represents a
loss.
With the stator row 40 present, as graphically
illustrated on the left side of Fig. 7, the stator vanes 46
change the direction of the airflow velocity vector. Because the
pitch of the vanes 46 is complementary to the pitch of the fan
blades 28, there is a resulting stator absolute discharge
velocity vector V as shown. This velocity vector has a
relatively small tangential or swirl component V~l. The
difference between the flow vectors V~0 and V~l represents a gain
in static pressure at the face of the condenser coil 22. Also,
as the flow vector V is redirected towards the axial direction,
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the air striking the coil 22 enters more nearly directly along
the axial direction, i.e., parallel with the fins 34, thereby
significantly reducing turbulence losses at the front face of the
coil 22. Hence, the static pressure requirements of the system
are reduced as well.
As illustrated in Fig. 8, the stator row 40 can produce a
significant static pressure rise when used with the propeller fan
(dash-line curve), as compared with the pressure attributable to
the propeller fan alone (solid-line curve).
The discussion above has assumed a frictionless, ideal
fan and a frictionless, ideal stator. However, losses will be
associated with swirl recovery because of viscous effects. As
illustrated in Fig. 9, if a rotor vane or blade 46' is selected
to effect complete redirection of the flow vector (as illustrated
by the inflow and outflow arrows), energy losses will occur
because of turbulent areas 38 on the surfaces of the stator
blades or vanes 46'. Generally, these losses increase in
relation to the degree to which the airflow is straightened.
Consequently, maximum benefit from the stator row 40 can occur
when the stator discharge or outflow angle is not truly axial, as
shown in the partial recovery mode view in Fig. 10.
In a practical embodiment, as graphically illustrated in
Fig. 10, the stator vane 46 has its geometry selected, relative
to that of the fan blade, to achieve maximum net recovery of the
swirl component. That is, in a practical embodiment, energy
losses contributable to both the swirl component V~l and to
turbulence caused by the presence of the stator vane 46, in
total, are minimized.
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When the stator row 40 incorporating the features
described above was incorporated with the outdoor side of a
packaged terminal air conditioner unit, a forty percent reduction
in shaft power required, and a 3.6 dBA reduction in noise were
measured, both directly attributable to the stator row 40.
While this invention was described hereinabove with
reference to a single preferred embodiment, it should be
understood that many possible modifications and variations could
be carried out by those skilled in the art without departing from
the scope and spirit of this invention, as defined in the
appended claims.
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